Stephen j



Reissued Sept. 27, 1927.

UNITED STATES V Re. 16,150

PATENT OFFICE.

STEPHEN J. HAYDE, OF KANSAS CITY, MISSOURI, ASSIGNOR TO AMERICAN AGGREGATE COMPANY, 01 KANSAS CITY, MISSOURI, A CORPORATION OF MISSOURI.

PROCESS OF PREPARING A MATERIAL SUITABLE FOR USE IN THE MANUFACTURE OFIOLDED ARTICLES.

No Drawing. Original No. 1,855,878, dated February 12, 1918, Serial No.178,836, filed July 3, 1917. Application for reissue filed February 28,1919. Serial No. 279,908.

My invention relates to the process of producing an aggregate ormaterial particularly adapted for use in the manufacture of brick, tile.terra cotta, and hke molded articles and for building, paving and otherpurposes, from a raw material the basis of which is clay, shale, orsimllar argillaceous material.

One of the objects thereof is to provide an improved process ofpreparing material for making articles of the class or k1nd referred toin which raw materials unsuitable for use in the manufacture of brickand for the other purposes stated as heretofore carried on may beutilized. Another object 18 to provide an improved process in which thebrick or other article produced is not subjected to a burning operationafter it has been given its final form, shape or outline, and also inwhich the articles may be produced at a much less expenditure of fueland in less time and with less labor than has heretofore commonly beenthe case. Other objects are to provide such other and furtherimprovements in and relating to the art of making brick and similarmolded articles from clay or equivalent argillaceous material as a basicraw material as are hereinafter pointed out and finally claimed. It isto be understood that my invention includes such variations andmodifications of the preferred procedure hereinafter referred to indetail and at length as will be obvious to those skilled in the art towhich my invention relates.

The basic raw material employed in mak- 'ing brick or analogous articlesin accordance with my invention is argillaceous or clayey in characterand is a material which will harden or form a clinker when subjected toa h gh temperature during the burning step of the process, Although therange of raw other substances or materials the presence of which woulddefeat the use of the raw material in ordinary brick making processes.In fact, and by way of example, a certain amount of lime producingmaterial, and of sand, are advantageous rather than otherwise in thebasic raw material employed in my process; whereas the presence of suchmaterials in clay to be used for making terialris found. The basic rawmaterial will,

during or after the mining operation in.

which it is removed from the original deposit, be broken up so as topass through a screen having about a four inch mesh, the large lumpsbeing rejected, or broken into finer particles before being used, inorder to facilitate the working of my process.

The raw material is next burned in a rotary or other type of kiln at ahigh temperature and for a comparatively short time. This burningtemperature should be in excess of 1500 degrees Fahrenheit, atemperature of from 1700 degrees to 2200 degrees Fahrenheit having beenfound suitable in the case of most raw argillaceous materials thus faremployed in carrying out my process; andthe said-high temperature ismaintained for the period of about two hours, as this treatment has beenfound to be the best suited formost raw materials. During this operationthe material or the argillaceous constituent thereof is converted intohard particles and clinkers, and it assumes such a state that it willwithstand the action of the elements without disintegration, and itbecomes a resistant material not liable to' change when the brick orother articles of which it forms the base and principal part are builtinto a permanent structure. The high temperature to which the materialis heated eliminates all silt therefrom, and the resulting 'burnedmaterial consists of indurated clay, inert material not changed by thehigh temperature to which the raw material is subjected, and lime to theextent that lime producing material is or may be present in the rawmaterial employed, all of which depend u on the characteristics andcomposition of t e original material, as will be appreciated.

After the raw material has beenburned as above, the same is deposited inpiles and permitted to cool slowly for a period of from six to twelvehours before bein crushed as will hereinafter appear. The breaking up orspontaneous disintegration of the material is prevented as much aspossible during the cooling thereof so that when the same is crushed thestronger and tougher portion will go through the crusher in as largelumps as the construction of the crusher will permit, while the weakerand more friable portion of the mass Wlll be broken into finer pieces(dependent upon the toughness of various portions of the materlal),whereby particles ranging in size from the coarsest which may passthrough the crusher to an impalpable dust will be produced at a singlecrushing operation.

After the material has cooled to such'an extent that the application ofwater thereto will not result in disintegration, and preferably beforeit is subjected to the crushing operation to be hereinafter referredto,water is'cominonly added to the material in order to slake such limeas may be present therein because of the presence of lime producingmaterial in the basic rawmaterial. The quantity of water thus used,however, is preferably as small as practicable, 1n order that thematerial may be dry or substantially dry when it is subjected to thenext step, the crushing operation of the process. The purpose of theapplication of water being to slake the lime produced during the burningoperation, it follows that if no lime producing materials or ingredientsare pres ent in the raw material, no water need be added. Lime or othermaterial which will slake will, however, ordinarily be present in theburned mixture, and therefore the mixture should be treated with waterbefore being crushed in order that the resultin lime may be thoroughlymixed with the hard material during the crushing operation, and in orderto insure completeness of the slaking of the lime. The water treatmentmay, however, be delayed until after the crushing operation, or omittedaltogether as a separate step as Water is added to the material at asubsequent stage in the carrying out of my process, as will hereinafterappear.

The burned, cooled, and water treated hard material is next crushed,preferably in a dry state or condition,-by means of any suitablecrushing mill or device, no pains being taken, however, to reduce all.the material to a uniform degree of fineness. In fact, as above stated,it is intended that the harder portions of the mass shall be as large asthe mechanical construction of the crusher will allow, while the weakerportions will be broken finer by the combined action of the crusher andof the harder portions passing therethrough and will form the morefinely crushed or ground portion of the crushed material. The crushingmill employed should be of such construction and so adjusted that thecoarser articles will be of such size that they will ass through ascreen having about a half inch mesh, and graduated down to impalpabledust. During this crushing operation and as above mentioned the slakedlime, or lime putty, becomes thoroughly mixed with the particles ofcrushed material, and the fineness to which the material is crushed isgoverned by the use to which it is to be ut, some articles being bestmade from nel and others from coarsely crushed material, as will beappreciated.

In case my process is to be employed in the manufacture of brick, thecrushed material produced as above is next mixed with Portland or othercement or lime (any kind or class of cement or lime may be used), andwater, and the plastic mass thus produced formed into brick. The brickmay be made by the puddling process which involves production of a thinand easily flowing mixture and the pouring-or tamping of the same intosuitable molds, by forming a thicker mixture and shaping the brick bymeans of a suitable molding machine or brick press, or otherwise, all asin present brick manufacturing operations and according to the kind ofbrick to be made and the choice or mechanical equipment of the maker, aswill be appreciated. Also, the brick may be sub.

ected to a repressing operation after preliminary formation thereof, ifdeemed desirable, the same as in brick manufacturing operations atpresent in use.

In case tile, terra cotta, or other shapes are to be produced the burnedand crushed material is mixed with cement or lime and g water to producea mixture of proper consistency, and the composition poured into orshaped by means of molds corresponding in form with the article to beproduced, as will be appreciated.

The brick or other article to be produced having thus been given theirproper finish and final form the cement or lime therein is permitted toharden and bind the comminuted hard basic material into a compact mass,during which they should be wetted other articles are ready for use.

It will be appreciated from the above thatv in making brick or-similarmolded articles in accordance with my invention the basic material orcomposition (the principal part of which is clay as will be appreciated)is one that has to be burned to render it suitable for use in brickmaking, that is, has to be burned in order to harden and convert it intoa form such that it will not be acted upon by the elements when thebrick produced has been built into a permanent structure, and also thatthe said basic material or composition is subjected to the burningprocess before the brick is formed therefrom, the brick being subjectedto no treatment involving a high temperature after they have been giventheir final shape or form.

Ittherefore follows that in brick made in accordance with my processthere is no shrinkage, cracking or distortion after molding due to asubsequent subjection thereof to a high temperature, such as occurs withbricks made in accordance with the ordinary brick making process inwhich the molded bricks are burned or subjected to a firing processduring which they are heated to a high temperature for several days, andalso that great economy so far as concerns the quantity of fuel used issecured, for brick made in accordance with the processes in common userequire heating to a moderate temperature for say five days in order todry them, and then to a much higher temperature for about the samelength of time to burn or fire themwhereas in the manufacture of brickin accordance with my process, the only heating necessary is that towhich the basic composition or raw material is subjected during theburning step of the process, and which is ordinarily completed in abouttwo hours.

Another feature of great practical importance in the manufacture ofbrick in accordance with my process is that raw mater'ial entirelyunsuited for the manufacture of brick in accordance with prior processesmay be utilized. In fact, any material containing a considerable amountof clay (enough so that it will harden upon burnsing) may be used, andthe presence of lime producing materials, gravel, sand, and variousother contaminating materials, substances or ingredients which render aclay entirely unfit for brick making as ordinarily carried on, areunobjectionable in making brick in accordance with. my process. In factI prefer to use a clay or argillaceous material containing aconsiderable quantity lime is molding or of liine producing material, asthe resulting s aked by the application of-water to the burned'rawmaterial, thus reducing the amount of cement or lime necessary to beused in preparing the material for the final shaping operation whichcompletes-th'e brick, except for the hardening or aging ste whichrequires time only and dur- 1n whic the cement or lime hardens. In ornary brick makin processes the presence of lime producing su stances inthe raw mater1al is most objectionable, for, in such a case, lime willbe produced during the burn mg or firing process (the final step inprior processes as will be appreciated) which will subsequently slake asmoisture gains access thereto, thus causing disintegration of the brick,often after they have been built into a permanent structure. In myprocess, however, such lime as may be produced by the burning step isslaked, preferably before the burned material ,is crushed as aboveexplained, and has a further opportunity to combine with 'water when thecrushed material is mixed with cement or lime and water prior to themolding operation, so that the presence of a certain quantity of limeproducing material in the raw material is advantageous rather thanotherwise, as it lessens the quantity of cement or lime neces- 9 sary tobe used, and the treatment of the mixture or composition during theprocess is such that no unslaked lime could in any event persist and bepresent in the completed brick.

The proportions which I have found to be desirable can be based on onepart of cement to six parts of the burned material after being crushed,and one part of lime putty. to four parts of the crushed burned shale,either proportion to vary according to conditions and to the strengthdesired.

1 The bricks or other articles made in accordance with my invention andin the manner hereinbefore pointed out at length have been found to bewell adapted to resist and H withstand the action of heat, as well alsoas the disintegrating action of water applied to them whenthey are in aheated condition, as commonly happens in a fire; and it has been foundin practice that they are but slightly affected by the action of heatand water at such times, and do not pop, crack,

craze or disintegrate to any considerable extent under the abovementioned and similar adverse treatments or circumstances.

Having thus described and explained my invention, I claim and desire tosecure by Letters Patent:

1'. The process of making aggregate suitable for the manufacture ofmolded articles which consists in burning a raw argillaceous materialcontaining a lime. producing substance, treating said burned materialwith water to slake the lime present therein, and crushing the burnedmaterial.

2. The process of making material suitable for the manufacture of moldedarticles which consists in burning a raw argillaceous materialcontaining a lime producing substance, treating said burned materialwith water to slake the lime present therein, crushing the burnedmaterial and mixing with the crushed material a material adapted toharden with water.

3. The process of making aggregate suitable for making brick or similararticles which consists in burning a raw argillaceous materialcontaining a substance commonly regarded as detrimental in brick makingprocesses, treating said burned material with water, before beingcrushed, and crushing the burned material.

4. The process of making aggregate suitable for manufacturing brick orsimilar articles whichconsists in burning a raw argillaceous materialcontaining a. substance commonly regarded as detrimental in brick makingprocesses, slowly cooling said burned material, and crushing the burnedmaterial.

5.,The process of making aggregate suitable for manufacturing brick orsimilar articles which consists in burning a raw argillaceous materialcontaining a substance conimo'nly regarded as detrimental in brickmaking processes, slowly cooling said burned material, treating saidburned material with water, and crushing the burned material.

6. The process of making aggregate suitable for manufacturing moldedarticles which consists in burning a suitable raw argillaceous materialat a temperature in excess of 1500 degrees Fahrenheit, for acomparatively short time, and crushing the burned material.

7. The process of making aggregate suitable for manufacturing moldedaticles which consists in burning a raw argillaceous material containinga lime producing substance at a temperature in excess of 1500 degreesFahrenheit, for a comparatively short time, treating said burnedmaterial with water to slake the lime present therein, and crushingthe-burned material.

8. The process of making aggregate suitable for manufacturing moldedarticles which consists in burning a raw argillaceous material at atemperature in excess of 1500 degrees Fahrenheit for a comparativelyshort time, slowly cooling said burned material, and crushing the burnedmaterial.

9. The process of making aggregate suitable for manufacturing moldedarticles which consists in burning a raw argillaceous materialcontaining a lime producing substance at a temperature in excess of 1500de grees Fahrenheit for a comparatively short time, slowly cooling saidburned material,

treating said burned material with water to slake the lime presenttherein, and crushing the burned material.

10. The process of making material suitable for manufacturing moldedarticles which consists in burning a raw argillaceous materialcontaining a lime producing substance at a temperature in excess of 1500degrees Fahrenheit for a comparatively short time, treating said burnedmaterial before being crushed with water to slake the lime presenttherein, crushing the burned material, and mixing cement with thecrushed material. I

11'. The process of making material suitable for manufacturing brick orsimilar molded articles which consists in burning a raw argillaceousmaterial containing a substance commonly regarded as detrimental inbrick making processes at a temperature in excess of 1500 degreesFahrenheit for a comparatively short time, crushing the burned material,and mixing cement with the crushed material.

12. The process of making aggregate suitable for manufacturing brick orsimilar molded articles which consists in burning a raw argillaceousmaterial containing a substance commonly regarded as detrimental inbrick making processes at a temperature in excess of 1500 degreesFahrenheit for a comparatively short time, treating said burned materialwith water, and crushing the burned material.

13. The process of making material suitable for manufacturing brick orsimilar articles which consists in burning a raw argillaceous materialcontaining a substance commonly regarded as detrimental iri brick makingprocesses at a temperature in excess of 1500 degrees Fahrenheit for acomparatively short time, treating said burned material with waterbefore being crushed, crushing the burned material, and mixingcementwith the crushed material.

14. The process of making aggregate suitable for manufacturing brick orsimilar molded articles which consists in burning a raw argillaceousmaterial containing a substance commonly regarded as detrimental inexcess of 1500 degrees Fahrenheit for a comparatively short time, slowlycooling said burned material, and crushing the burned material.

15. The process of making material suitable for manufacturing brick orsimilar molded articles which consists in burning a raw argillaceousmaterial containing a substance commonly regarded as detrimental inbrick making processes at a. temperature in excess of 1500 degreesFahrenheit for a comaratively short time, slowly cooling said burnedmaterial, treating said burned material with water, crushing the burnedmaterial, and mixing cement or 'lime with the crushed burned material.

STEPHEN J. HAYDE.

